Systems and methods for maintaining airflow in abrasive blasting systems

ABSTRACT

An abrasive blasting system and associated methods are disclosed. The abrasive blasting system includes a blast enclosure that receives a component to be blasted by an abrasive media. A dust collector is fluidly coupled to the blast enclosure and collects the dust from the blast enclosure generated by the blasting of the component by the abrasive media. The dust collector includes a filter and a fan having a motor. The filter is disposed upstream of the fan. The fan draws air and dust from the blast enclosure into the dust collector and draws air through the filter to separate the dust from the air. A sensor monitors a condition of the abrasive blasting system and generates a condition signal corresponding to the condition. A controller receives the condition signal and controls the fan based on the condition signal.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/024,700, filed May 14, 2020, the entirety of which is hereby incorporated by reference for all purposes.

FIELD

The present disclosure generally relates to abrasive blasting systems, and more particularly to systems and methods for maintaining airflow in abrasive blasting systems.

BACKGROUND

Abrasive blasting systems are used to forcibly propel a stream of abrasive material or media, such as sand, glass, garnet, aluminum, etc., against a surface of an object. This can be done to remove a material (e.g., paint) from the surface of the object, smooth or roughen the surface of the component, and/or shape the surface of the component. Typically, a pressurized fluid, such as pressurized (e.g., compressed) air, is used to force the abrasive media against the surface of the component.

SUMMARY

In one aspect, an abrasive blasting system comprises a blast enclosure configured to receive a component therein to be blasted by an abrasive media. A dust collector is fluidly coupled to the blast enclosure and is configured to collect dust from the blast enclosure generated by blasting of the component by the media. The dust collector includes a filter and a fan having a motor. The filter is disposed upstream of the fan. The fan is configured to draw air and dust from the blast enclosure into the dust collector and draw air through the filter to separate the dust from the air. A sensor is configured to monitor a condition of the abrasive blasting system and to generate a condition signal corresponding to the condition. A controller is configured to receive the condition signal and to control the fan based on the condition signal.

In another aspect, an abrasive blasting system comprises a blast enclosure configured to receive a component therein to be blasted by an abrasive media. A dust collector is fluidly coupled to the blast enclosure and is configured to collect dust from the blast enclosure generated by blasting of the component by the media. The dust collector includes a filter and a fan having a motor. The filter is disposed upstream of the fan. The fan is configured to draw air and the dust from the blast enclosure into the dust collector and draw air through the filter to separate the dust from the air. A sensor is configured to monitor a condition of the abrasive blasting system and to generate a condition signal corresponding to the condition. A controller is configured to estimate an end of a life of the filter based on the condition signal.

In another aspect, a method of operating an abrasive blasting system comprises blasting a component within a blast enclosure by an abrasive media, moving air with a fan having a motor from the blast enclosure to a dust collector to collect dust from the blast enclosure, the dust collector having a filter, monitoring a condition of the abrasive blasting system; and controlling the fan based on the condition.

Other objects and features of the present disclosure will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of an abrasive blasting system according to one embodiment of the present disclosure;

FIG. 2 is an illustration of a first example of an abrasive blasting system according to the present disclosure;

FIG. 3 is schematic diagram of a control system of the abrasive blasting system of FIG. 2;

FIG. 4 is a flow diagram illustrating the process for monitoring and adjusting the amount of air flow for the abrasive blasting system of FIG. 2;

FIG. 5 is an exemplary motor speed versus time graph for a motor of the abrasive blasting system of FIG. 2;

FIG. 6 is flow diagram illustrating the process for monitoring the life of a filter of the abrasive blasting system of FIG. 2;

FIG. 7 is an illustration of a second example of an abrasive blasting system according to the present disclosure;

FIG. 8 is a flow diagram illustrating the process for monitoring and adjusting the amount of air flow for the abrasive blasting system of FIG. 7;

FIG. 9 is an illustration of a third example of an abrasive blasting system according to the present disclosure;

FIG. 10 is a flow diagram illustrating the process for monitoring and adjusting the amount of air flow for the abrasive blasting system of FIG. 9; and

FIG. 11 is an illustration of a fourth example of an abrasive blasting system according to the present disclosure.

Corresponding reference numbers indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Referring to FIG. 1, an abrasive blasting system according to one embodiment of the present disclosure is generally indicated at reference numeral 110. The abrasive blasting system 110 can include a blast enclosure 112, such as a blast cabinet or a blast room, a media reclaimer 114 and a dust collector 116. The system 110 can include fluid conduits or ducting 118 (e.g., hose, conduit, etc.) operatively connecting the enclosure 112, the media reclaimer 114, and the dust collector 116 for movement of air, dust, and/or media between these respective components. Broadly, the enclosure 112, the media reclaimer 114, the dust collector 116, and/or the ducting 118 define gas flow passaging through which gas, dust, and/or media moves downstream. Generally speaking, gas, media, and dust (driven by a fan system) flows from the enclosure 112 downstream from the enclosure 112 to the media reclaimer 114, and gas and dust flow downstream from the media reclaimer to the dust collector 116.

The blast enclosure 112 is configured to receive the object therein to be blasted by the abrasive media. Any suitable blast enclosure can be used without departing from the scope of the present disclosure. The blast enclosure 112 will typically include a blast gun 120 for directing the abrasive media at the object. The blast enclosure 112 also include an air inlet 126 to permit air to be drawn into the blast enclosure (broadly, the system 110). As the component is blasted, dust is generated in the blast enclosure 112. The media reclaimer 114 is configured to separate the abrasive media from the dust, both of which are carried by air from the blast enclosure 112 to the media reclaimer via one or more fluid conduits 118 (e.g., ducting). The separated abrasive media can then be re-used to blast the component again. The media reclaimer 114 includes a separator 122 configured to separate the abrasive media from the dust and a hopper 124 (broadly, a pressure vessel) configured to hold the supply of media for the blast enclosure 112 and receive the separated media from the separator. One or more fluid conduits 118 transports the media from the hopper 124 to the blast enclosure 112 (e.g., blast gun 120). Generally, the hopper 124 is disposed below the separator 122. The separator 122 imparts a cyclone effect into the airflow to separate the abrasive media from the dust. In certain embodiments, the media reclaimer 114 may include a fan (not shown) having a motor (e.g., a media reclaimer fan motor) configured to facilitate the movement of the air from the blast enclosure into the media reclaimer and/or from the media reclaimer to the dust collector. Other media reclaimers lack a fan and rely on a fan of the dust collector downstream from the media reclaimer. Any suitable media reclaimer can be used without departing from the scope of the present disclosure. The dust collector 116 is configured to collect the dust (e.g., the dust from the blast enclosure 112), after the dust has been separated from the abrasive media by the media reclaimer 114. One or more fluid conduits 118 transports the dust carried by the air from the media reclaimer 114 to the dust collector 116.

The dust collector 116 includes a fan 128 to draw the air into the dust collector from the blast enclosure 112 and/or the media reclaimer 114. In some embodiments, the fan 128 draws the air, dust and abrasive media from the blast enclosure 112 and into the media reclaimer 114. The fan 128 then draws the air and dust from the media reclaimer 114 into the dust collector 116. The dust collector 116 includes at least one filter 130 (e.g., a dust or filter cartridge) configured to separate the dust from the air. The filter 130 is disposed upstream of the fan 128 such that the fan draws the air through the filter to separate the dust from the air. After the dust is separated from the air, the air is exhausted by the fan 128. The fan 128 includes a motor 132 and a fan blade (e.g., blade assembly or bladed wheel) (not shown) operatively coupled to the motor and configured to draw air through the abrasive blasting system when rotated by the motor. The dust collector 116 includes a waste drum 136 for collecting the dust. The dust collector 116 includes an exhaust 134 for exhausting the air, after the dust has been separated from the air. Any suitable dust collector can be used without departing from the scope of the present disclosure.

The dust collector fan 128 and optional media reclaimer fan (and their associated motors) can be referred to broadly as a fan system. It will be appreciated that a fan system of the present disclosure can include one or more fans and one or more fan motors (each associated with one or more fans), and that the fans can be positioned at various locations in the system (e.g., media reclaimer or dust collector, etc.). As explained in further detail below, operation of the fan system (e.g., media reclaimer and/or dust collector fan(s)) can be controlled (e.g., responsive to a condition signal) to extend effective life of a dust filter 130. For example, speed of one or more fans could be changed and/or one or more fans could be turned on/off to increase airflow in the gas flow passaging. If the media reclaimer fan is used, the controller may control the media reclaimer fan motor via a variable frequency drive coupled thereto in a similar manner as the motor 132 of the dust collector 116.

Generally, the abrasive blasting system 110 can be thought of as having two different subsystems, a media delivery subsystem and a recovery and reclamation subsystem. The media delivery subsystem includes the blast enclosure 112, the hopper 124 of the media reclaimer 114 and any associated valves and fluid conduits 118 (e.g., hoses) used to fluidly connect the hopper to the blast enclosure. The recovery and reclamation subsystem includes the separator 122 of the media reclaimer 114 (and optional media reclaimer fan), the dust collector 116, and any associated valves and fluid conduits 119 (e.g., hoses) used to fluidly connect the blast enclosure 112, the separator and the dust collector together. It is desirable to maintain appropriate air flow velocity in the recovery and reclamation subsystem and maintain appropriate pressure drop across the media reclaimer 114 to provide efficient operation of the recovery and reclamation subsystem and reduce disposal of good media. In conventional systems, as the filter clogs, resistance to air flow increases, which results in decreased effectiveness of the reclaimer and thus inefficient separation of good media from bad media and increased routing of good media to the trash bin.

The abrasive blasting system 110 can be a suction based system or a pressure based system, the difference between the two being the manner in which the abrasive media is introduced into the pressurized fluid. In a suction abrasive blasting system, the abrasive media is drawn from the hopper 124 of the media reclaimer 114 into the flow of pressurized fluid and toward the blast gun 120 by suction created in one or more conduits 118 (e.g., media supply lines) by the flow of pressurized fluid. In a pressure abrasive blasting system, the abrasive media is usually introduced to the flow of pressurized fluid from the hopper 122 (e.g., pressure vessel) of the media reclaimer 114 generally by gravity and pushed by the flow of pressurized fluid to the blast gun 120 by the pressurized fluid.

In furtherance of the general explanation above of abrasive blasting systems of the present disclosure, specific examples will be discussed below in further detail. It will be appreciated that the examples are provided by way of example without limitation. It will be understood that changes can be made to the examples without departing from the scope of the present disclosure.

First Example of an Abrasive Blasting System

Referring to FIGS. 2-6, a first example of an abrasive blasting system according to the present disclosure is generally indicated by reference numeral 210. The abrasive blasting system 210 of FIG. 2 is generally analogous to the abrasive blasting system 110 of FIG. 1. Thus, for ease of comprehension, where similar, analogous or identical parts are used, reference numerals “100” units higher are employed. Accordingly, unless clearly stated or indicated otherwise, the above descriptions regarding the abrasive blasting system 110 of FIG. 1 also apply to the abrasive blasting system 210 of FIG. 2. In this example, the abrasive blasting system 210 includes a blast enclosure 212 (e.g., blast cabinet), a media reclaimer 214 and a dust collector 216, as described above. It is understood that other configurations are within the scope of the present disclosure. As will be explained in more detail below, the abrasive blasting system 210 is able to adjust the speed of the fan motor 232 to ensure a proper amount of air (e.g., airflow) is being moved through the abrasive blasting system even as the filter 230 becomes clogged with dust and obstructs the airflow. In addition, the abrasive blasting system 210 is able to estimate the upcoming end of life of the filter 230 (e.g., remaining filter life) and determine when the filter needs to be replaced (when the end of life has been reached).

The abrasive blasting system 210 includes a sensor 238 configured to monitor a condition of the abrasive blasting system and to generate a condition signal corresponding to the condition. For example, the condition can relate or correspond to the airflow driven by the fan system. Referring to FIG. 3, the abrasive blasting system 210 also includes a controller 250 communicatively coupled to the sensor 238. The controller 250 is communicatively coupled to the fan system (e.g., one or more motors, such as the motor 232 of the dust collector, of the fan system). The controller 250 is configured to receive the condition signal and to control the at least one motor (e.g., to increase fan speed), and/or to turn one or more fans on/off, based on the condition signal, to adjust the airflow in the gas passaging. For example, the at least one motor may be an electric motor coupled to a variable frequency drive that controls the speed of the motor. In such case, the controller 250 controls the speed of the motor via the variable frequency drive.

Generally, the controller 250 includes a CPU or processor 252 and a RAM or memory 254 (broadly, non-transitory computer-readable storage medium). The processor 252 provides the computing engine that drives the operation of the controller 250. Broadly, the tangible storage medium 254 includes (e.g., stores) processor-executable instructions for controlling the operation of the processor 252. The instructions embody one or more of the functional aspects of the controller 250, as described herein, with the processor 252 executing the instructions to perform said one or more functional aspects.

The controller 250 is connected to a user interface 256 having a user input 258 (e.g., button, switch, actuator, etc.) and user output 260 (e.g., display). In one embodiment, the user input 258 and user output 260 are integrated into the same component, such as a touch screen display. Using the user input 258 the user can enter, modify and/or save operating parameters of the abrasive blasting system. For example, using the user input 258, the user can inform the abrasive blasting system 210 when the filter 230 has been replaced. The user output 260 provides indications (e.g., visual indications) to the user regarding the status of the abrasive blasting system 210. The user output 260 can provide alarms, alerts, etc. regarding the system 210. For example, the user output 260 can provide an alert or notification to the user when it is time to replace the filter 230.

The controller 250 is configured to adjust the speed of the motor, such as the dust collector fan motor 232, to ensure a proper amount of air (e.g., airflow) is being moved through the abrasive blasting system 210 (e.g., being drawn from the blast enclosure into the dust collector) even as the filter 230 becomes clogged with dust and obstructs the airflow. It is desirable to ensure that an appropriate amount of airflow is being generated by the fan 228. If the fan 228 is providing an insufficient amount of airflow through the abrasive blasting system 210, dust and/or abrasive media may build up in the blast enclosure 212 and/or the media reclaimer 214 may not function properly. A sufficient amount of airflow is needed for several reasons. First, a sufficient amount of airflow must be flowing through the media reclaimer 214 for the media reclaimer to function efficiently (e.g., separate the good media from the dust). The media reclaimer 214 will work inefficiently (e.g., fail to completely separate the good media from the dust) when an insufficient amount of airflow is flowing through the media reclaimer. As a result, when an insufficient amount of airflow flows through the media reclaimer 214, some of the media will not be separated from the dust, but instead, travel to the dust collector 216 with the dust. This unseparated media is then thrown away with the dust, increasing amount and cost of media used by the blasting system 210. In addition, a sufficient amount of airflow must be flowing through the media reclaimer 214 in order to move the dust through the media reclaimer and into the dust collector 216. If the amount of airflow is insufficient, the entrained dust may fall out of the airflow before reaching the dust collector 216. Moreover, by ensuring a proper or sufficient amount of airflow is being moved through the abrasive blasting system 210, as described herein, the performance of the abrasive blasting system (e.g., the separation of the media and the dust) is maintained over the effective life of the filter 230. In conventional blasting systems, the performance of the blasting system decreases rapidly as the filter becomes clogged. Operating the abrasive blasting system 210 as described herein may also increase the life of the filter 230.

As air is drawn through the filter 230 in the dust collector 216, the filter separates the dust from the air. This is primarily done by trapping the dust in the filter 230. As more and more dust becomes trapped in the filter 230, the filter creates a greater impediment or resistance to the flow of air therethrough. This greater resistance to airflow results in a reduction in the amount (e.g., CFM) of air being moved through the abrasive blasting system 210 by the fan 228, when the motor 232 of the fan operates at the same speed. Accordingly, to increase the flow air in the system back to an acceptable level, the speed of one or more fan motors, such as the dust collector fan motor 232, may be increased to increase the speed of one or more fans, such as the dust collector fan 228, of the fan system to compensate for the greater resistance to the airflow due to the clogged (e.g., clogging) filter 230.

The controller 250 is configured to determine the amount of airflow through the abrasive blasting system 210 and to control the fan system (e.g., adjust the speed of the motor, such as the dust collector fan motor 232, accordingly) to ensure a proper level of airflow (e.g., a threshold level of airflow) is being achieved. The threshold level of airflow may be a minimum value of or a range of airflow (e.g., a minimum CFM or range of CFM, such as at least 900 CFM, or 600 CFM to 1200 CFM) at which the abrasive blasting system 210 desirably operates. The threshold level of airflow may be different for different abrasive blasting systems and different media types. The controller 250 monitors (e.g., periodically or continuously monitors) the condition signal from the sensor 238. The controller 250 is configured to change the amount of airflow (e.g., speed of the motor) based on the condition signal. For example, when the controller 250 determines the amount of airflow is too low, based on the condition signal, the controller may increase the speed of the motor, such as the dust collector fan motor 232, via the variable frequency drive. The memory 254 of the controller 250 may store a reference guide used by the controller to associate the value of the monitored condition with a specific amount of air flow. The controller 250 uses the reference guide to determine the amount of air being moved through the abrasive blasting system 210 based on the value of the monitored condition. The reference guide may be a table or an equation developed via prior testing.

In the example shown in FIG. 2, the sensor 238 is a current sensor and the condition monitored is the current drawn by the motor 232 to power the fan 228. The amount of current drawn by the motor 232 correlates to the amount of air being moved through the abrasive blasting system 210 for a given motor speed. As the filter 230 becomes clogged, the filter presents greater resistance to air flow. Accordingly, air flow decreases, and the current drawn by the motor 232 decreases. A percentage decrease in current drawn by the motor 232 can indicate a need to increase the speed of the motor to maintain desired air flow moved through the abrasive blasting system 210. In this embodiment, the reference guide used by the controller 250 associates the value of the current draw of the motor 232 with the speed of the motor (which is known by the controller because the controller sets the speed of the motor) to determine the amount of air being moved through the abrasive blasting system 210. Thus, the controller 250 is able to determine the amount of air being moved through the abrasive blasting system 210 based on the current drawn by the motor 232, as monitored by the current sensor 238. When the controller 250 determines there is not enough air moving through the abrasive blasting system 250, the controller adjusts operation of the fan system (e.g., the dust collector fan 228) to increase the amount of airflow to an acceptable level. For example, the controller 250 may continuously or periodically monitor the airflow through the abrasive blasting system 210 and adjust the motor's 232 speed accordingly. Thus, the controller 250 is able to maintain the appropriate amount of airflow through the abrasive blasting system 210 to maintain effective operation of the media reclaimer 214 over the useful life of the filter 230 (e.g., as the filter traps more and more dust creating a greater resistance to the flow of air). This may also extend the effective life of the filter 230.

An exemplary flow diagram illustrating the process for monitoring and adjusting the amount of air flow by the controller 250 in this embodiment is shown in FIG. 4.

As the controller 250 operates the abrasive blasting system, the controller monitors the current draw of the motor 232 via the current sensor 238. The controller 250 uses the value of the current draw and the speed of the motor 232 to determine the amount of airflow using the reference guide. If the determined amount of airflow has not deviated from the threshold level, the controller 250 continues to monitor the condition (e.g., the current draw). If the determined amount of airflow deviates from the threshold level, the controller 250 determines if the speed of the motor 232 can be increased (e.g., has the maximum desired speed of the motor been reached). If the speed of the motor 232 can be adjusted (e.g., the motor can go faster or slower), the controller 250 adjusts the speed of the motor and then continues to monitor the current draw. This process repeats until the amount of airflow no longer deviates from the threshold level. If the speed of the motor 232 cannot be adjusted (e.g., the motor is already going as fast as possible), the controller 250 indicates to a user via the user interface 256 that the filter 230 needs to be changed and/or shuts down the abrasive blasting system 210. The controller 250 may also prevent the abrasive blasting system 210 from operating until the filter 230 is replaced.

In addition, the controller 250 is also able to estimate the upcoming end of life (e.g., remaining life) of the filter 230 and determine when the filter needs to be replaced (when the end of life has been reached). As the filter 230 becomes more clogged and creates a greater resistance to the flow of air, the controller 250 continues to adjust operation of the fan system (e.g., the dust collector fan motor 232) to compensate for the increased resistance. Eventually, the at least one fan motor will be running at a maximum desired speed. At this maximum desired speed, as the filter 230 continues to create a greater resistance, the current drawn by the motor 232 will continue to decrease. Eventually, the current drawn by the motor 232 at the maximum desired speed of the motor will be too low (indicating insufficient flow) to continue operating the abrasive blasting system 210. At this point, the filter 230 needs to be replaced. Replacing the filter 230, will decrease the resistance to the airflow through the abrasive blasting system 210, allowing the motor 232 to operate under normal conditions (e.g., at lower speeds). Accordingly, by knowing the speed of the motor 232 and the amount of current drawn by the motor, via the current sensor 238, the controller 250 can determine when the filter 230 needs to be replaced. Moreover, by tracking the increase in speed of the motor 232 (and/or drawn current) over time, the controller 250 can estimate (e.g., extrapolate) the remaining life of the filter 230 (when the filter will need to be replaced) and/or when the filter's effective life has ended. The controller 250 can be configured to provide an indication of this information (e.g., estimated upcoming end of life of filter (e.g., indicate number of days until end of life, or indicate future end of life date) and/or filter needs to be replaced) to a user via the user interface 256 (e.g., audio and/or visual signal or alert via the user output 260 (e.g., display) of the user interface associated with the system 210).

Referring to FIG. 5, an exemplary motor speed versus time graph for the motor 232 of the abrasive blasting system 210 is illustrated. When the motor 232 reaches its maximum desired speed and rated current draw, and the current draw continues to decrease, it is time to replace the filter 230. It is understood the current draw at each motor speed will vary over time.

Referring to FIG. 6, an exemplary flow diagram illustrating the process for monitoring, by the controller 250, the life of the filter 230 is shown.

To estimate when the filter 230 will need to be replaced (e.g., the remaining life of the filter), the controller 250 operates the motor 232 at a first speed starting at a first time. The controller 250 continues to operate the motor 232 at the first speed until the speed of the motor needs to be adjusted, as explained above. When the controller 250 adjusts the speed of the motor 232, the controller operates the motor at a second speed. Most likely, the second speed will be greater than the first speed. The second time is the point at which the controller 250 adjusts the speed of the motor 232 to the second speed from the first speed. The controller 250 then determines the period of time between the first and second times and the speed difference between the first and second speeds. The controller 250 than takes the period of time, the speed difference, the second speed and the maximum speed of the motor to estimate the remaining life of the filter 230. In one embodiment, the following equation may be used, although other methods of estimating the remaining life of the filter 230 is within the scope of the present disclosure:

$T_{R} = \frac{\left( {T_{2} - T_{1}} \right)\left( {S_{m} - S_{2}} \right)}{\left( {S_{2} - S_{1}} \right)}$

T_(R) is the time remaining in the life of the filter, T₁ is the first time, T₂ is the second time, S_(m) is the maximum speed of the motor 232, S₁ is the first speed and S₂ is the second speed. The time (T_(R)) can then be used to project the date the filter 230 will need to be replaced. If the time (T_(R)) is zero, there is no remaining filter life. This equation implies a linear relationship between the motor speed and time to determine the time remaining in the life of the filter 230. In other embodiments, the relationship may be more accurately represented as a trade-off curve or an exponential curve.

Second Example of an Abrasive Blasting System

Referring to FIGS. 7 and 8, a second example of an abrasive blasting system according to the present disclosure is generally indicated by reference numeral 310. The abrasive blasting system 310 of FIG. 7 is generally analogous to the abrasive blasting system 210 of FIG. 2. Thus, for ease of comprehension, where similar, analogous or identical parts are used, reference numerals “100” units higher are employed. Accordingly, unless clearly stated or indicated otherwise, the above descriptions regarding the abrasive blasting system 210 of FIG. 2 also apply to the abrasive blasting system 310 of FIG. 7. This abrasive blasting system 310 is generally the same as the abrasive blasting system 210 of the first example, except as described below. In this example, the sensor 338 is a pitot tube sensor (broadly, a velocity sensor) and the condition monitored is the velocity of the airflow through the abrasive blasting system 310. In the illustrated embodiment, the pitot tube sensor 338 is downstream of the fan 328 and measures the velocity of the air being exhausted from the abrasive blasting system 310 (e.g., outlet velocity). The pitot tube sensor 338 can be disposed at other positions along the abrasive blasting system 310. For example, the pitot tube sensor 338 can be disposed upstream of the fan 328. It is desirable to position the pitot tube sensor 338 downstream of the fan 328 (e.g., in the exhaust) because the airflow is the cleanest (e.g., the air includes no dust or media), resulting in better sensor performance and life.

The velocity of the airflow correlates to the amount of air being moved by the fan 328 through the abrasive blasting system 310. For example, a smaller velocity is associated with a smaller amount of air being moved, and thus a greater resistance to the flow of air through the system 310 due to the filter 330. Thus, the velocity of the airflow also correlates to the amount of air being moved through the abrasive blasting system 310 for a given motor speed. The controller 350 is able to determine the amount of air being moved through the abrasive blasting system 310 based on the velocity of the airflow, as monitored by the pitot tube sensor 338. In this embodiment, the controller 350 uses the reference guide to determine the amount of air being moved through the abrasive blasting system 310 based on the value of the velocity of the airflow. In one embodiment, the reference guide is velocity vs CFM chart for the abrasive blasting system 310 the controller 350 accesses to match the measured velocity with a corresponding CFM or the controller may use an equation to determine the CFM based on the area of the airflow at the pitot tube sensor 338. When the controller 350 determines there is not enough air moving through the abrasive blasting system 310, the controller adjusts operation of the fan system (e.g., increases the speed of the at least one fan motor, such as the dust collect fan motor 332) to increase the amount of airflow to an acceptable level, as described above. The controller 350 can be configured to provide an indication of this information (e.g., estimated upcoming end of life of filter and/or filter needs to be replaced) to a user via the user interface 356 (e.g., audio and/or visual signal or alert via a user output 360 (e.g., display) of the user interface associated with the system 310).

Referring to FIG. 8, an exemplary flow diagram illustrating the process for monitoring and adjusting the amount of air flow by the controller 350 in this embodiment is shown.

As the controller 350 operates the abrasive blasting system 310, the controller monitors the velocity of the airflow at a location in the abrasive blasting system. The controller 350 uses the value of the velocity to determine the amount of airflow using the reference guide. If the determined amount of airflow has not deviated from the threshold level, the controller 350 continues to monitor the condition (e.g., the velocity). If the determined amount of airflow deviates from the threshold level, the controller 350 determines if the speed of the motor 332 can be increased (e.g., has the maximum or minimum speed of the fan 328 been reached). If the speed of the motor 332 can be adjusted (e.g., the motor can go faster or slower), the controller 350 adjusts the speed of the motor and then continues to monitor the velocity. This process repeats until the amount of airflow no longer deviates from the threshold level. If the speed of the motor 332 cannot be adjusted (e.g., the motor is already going as fast as possible), the controller indicates to a user via the user interface 356 that the filter 330 needs to be changed and/or shuts down the abrasive blasting system 310. The controller 350 may also prevent the abrasive blasting system 310 from operating until the filter 330 is replaced.

In addition, the controller 350 is also able to estimate the remaining life of the filter 230 and determine when the effective life of the filter has ended (filter needs to be replaced). As mentioned above, the controller 350 continues to adjust operation of the fan system (e.g., increase the speed of the motor, such as the dust collector fan motor 332) to compensate for the increased resistance from the filter 330. The filter 330 needs to be replaced when the velocity of the airflow can no longer be maintained at the acceptable level (e.g., the at least one motor's speed cannot be increased) for appropriate operation of the abrasive blasting system 310. Replacing the filter 330, will decrease the resistance to the airflow through the abrasive blasting system 310, allowing the motor 332 to operate under normal conditions (e.g., at lower speeds). Accordingly, by knowing the velocity of the airflow, via the pitot tube sensor 338, the controller 350 can determine when the filter 330 needs to be replaced. Moreover, by tracking the increase in motor speed over time due to maintaining the airflow's velocity at an acceptable level, the controller 350 can estimate when the motor 332 will reach its maximum speed (thereby estimating the remaining life of the filter 330), and when the filter needs to be replaced, as described in reference to FIG. 6. The controller 350 can be configured to provide an indication of this information (e.g., remaining filter life and/or when filter needs replacement) to a user via the user interface 356 (e.g., audio and/or visual signal or alert via a user output 360 (e.g., display) of the user interface associated with the system 310).

Third Example of an Abrasive Blasting System

Referring to FIGS. 9 and 10, a third example of an abrasive blasting system according to the present disclosure is generally indicated by reference numeral 410. The abrasive blasting system 410 of FIG. 8 is generally analogous to the abrasive blasting system 310 of FIG. 7. Thus, for ease of comprehension, where similar, analogous or identical parts are used, reference numerals “100” units higher are employed. Accordingly, unless clearly stated or indicated otherwise, the above descriptions regarding the abrasive blasting system 310 of FIG. 7 also apply to the abrasive blasting system 410 of FIG. 9. This abrasive blasting system 410 is generally the same as the abrasive blasting systems 110, 210, 310 of the examples above, except as described below. In this example, the sensor 438 is a static pressure sensor and the condition monitored is the static pressure of the airflow moving through the abrasive blasting system 410. In the illustrated embodiment, static pressure sensor 438 is disposed downstream of the fan 428 in the exhaust and measures the static pressure (e.g., positive static pressure) of the air being exhausted from the abrasive blasting system 410. The static pressure sensor 438 can be disposed at other positions along the abrasive blasting system 410. For example, the static pressure sensor 438 can be disposed upstream of the fan 428. It is desirable to position the static pressure sensor 438 downstream of the fan 428 (e.g., in the exhaust) because the airflow is the cleanest (e.g., the air includes no dust or media), resulting in better sensor performance and life.

The abrasive blasting system 410 of FIG. 9 with the static pressure sensor 438 works similar to the abrasive blasting system 310 of FIG. 7 with the pitot tube sensor 338. The static pressure of the airflow correlates to the amount of air being moved by the fan blade or wheel (broadly, the dust collector fan 428) through the abrasive blasting system 410. For example, a smaller static pressure in the exhaust is associated with a smaller amount of air being moved, and thus a greater resistance to the flow of air through the system 410 due to the filter 430. Thus, the static pressure of the airflow also correlates to the amount of air being moved through the abrasive blasting system 410 for a given motor speed. The controller 450 is able to determine the amount of air being moved through the abrasive blasting system 410 based on the static pressure of the airflow, as monitored by the static pressure sensor 438. In this embodiment, the controller 450 uses the reference guide to determine the amount of air being moved through the abrasive blasting system 410 based on the value of the static pressure of the airflow. When the controller 450 determines there is not enough air moving through the abrasive blasting system 410, the controller adjusts operation of the fan system (e.g., increases the speed of the at least one motor, such as the dust collector fan motor 432) to increase the amount of airflow back to the acceptable level, as described above. The controller 450 can be configured to provide an indication of this information (e.g., remaining filter life and/or when filter needs replacement) to a user via the user interface 456 (e.g., audio and/or visual signal or alert via a user output 460 (e.g., display) of the user interface associated with the system 410).

Referring to FIG. 10, an exemplary flow diagram illustrating the process for monitoring and adjusting the amount of air flow by the controller 450 in this embodiment is shown.

As the controller 450 operates the abrasive blasting system 410, the controller monitors the static pressure of the airflow at a location (e.g., exhaust) in the abrasive blasting system. The controller 450 uses the value of the static pressure to determine the amount of airflow using the reference guide. If the determined amount of airflow has not deviated from the threshold level, the controller 450 continues to monitor the condition (e.g., the static pressure). If the determined amount of airflow deviates from the threshold level, the controller 450 determines if the speed of the motor 432 can be increased (e.g., has the maximum or minimum speed of the fan been reached). If the speed of the motor 432 can be adjusted (e.g., the motor can go faster or slower), the controller 450 adjusts the speed of the motor and then continues to monitor the static pressure. This process repeats until the amount of airflow no longer deviates from the threshold level. If the speed of the motor 432 cannot be adjusted (e.g., the motor is already going as fast as possible), the controller 450 indicates to a user via the user interface 456 that the filter 430 needs to be changed and/or shuts down the abrasive blasting system 410. The controller 450 may also prevent the abrasive blasting system 410 from operating until the filter 430 is replaced.

Similarly, the controller 450 is also able to estimate the remaining life of the filter 430 and determine when the filter has reached the end of its life (needs to be replaced). The filter 430 needs to be replaced when the static pressure of the airflow can no longer be maintained at the acceptable level (e.g., the motor's speed cannot be increased) for appropriate operation of the abrasive blasting system 410. Replacing the filter 430, will decrease the resistance to the airflow through the abrasive blasting system 410, allowing the motor 432 to operate under normal conditions (e.g., at lower speeds). Accordingly, by knowing the static pressure of the airflow, via the static pressure sensor 438, the controller 450 can determine when the filter needs to be replaced. Moreover, by tracking the increase in motor speed over time due to maintaining the airflow's static pressure at an acceptable level, the controller 450 can estimate when the motor 432 will reach its maximum speed, thereby estimating the remaining life of the filter 430 and when the filter will need to be replaced, as described above in reference to FIG. 6. The controller 450 can be configured to provide an indication of this information (e.g., estimated upcoming end of life of filter and/or filter needs to be replaced) to a user via the user interface 456 (e.g., audio and/or visual signal or alert via the user output 460 (e.g., display) of the user interface associated with the system 410).

Fourth Example of an Abrasive Blasting System

Referring to FIG. 11, a fourth example of an abrasive blasting system according to the present disclosure is generally indicated by reference numeral 510. The abrasive blasting system 510 of FIG. 11 is generally analogous to the abrasive blasting system 410 of FIG. 9. Thus, for ease of comprehension, where similar, analogous or identical parts are used, reference numerals “100” units higher are employed. Accordingly, unless clearly stated or indicated otherwise, the above descriptions regarding the abrasive blasting system 410 of FIG. 9 also apply to the abrasive blasting system 510 of FIG. 11. This abrasive blasting system 410 is generally the same as the abrasive blasting systems 110, 210, 310, 410 of the examples above, except as described below. In this example, the sensor 538 is a static pressure sensor and the condition monitored is the static pressure of the airflow in the abrasive blasting system 510. In this example, static pressure sensor 538 is disposed in the blast enclosure 512 (e.g., upstream of the fan 528) and measures the static pressure of the air in the blast enclosure. As mentioned above, the static pressure sensor 538 can be disposed at other positions along the abrasive blasting system 510. For example, the static pressure sensor 538 can be disposed at other locations upstream of the fan 528, or could be disposed downstream of the fan.

The abrasive blasting system 510 of FIG. 11 with the static pressure sensor 538 in the blast enclosure 512 works similar to the abrasive blasting system 410 of FIG. 9 with the static pressure sensor 438 in the exhaust. Thus, the above descriptions regarding the operation of the abrasive blasting system 410 of FIG. 9 also apply to the operation of the abrasive blasting system 510 of FIG. 11. For example, an exemplary flow diagram for monitoring and adjusting the amount of airflow by the controller 550 of the abrasive blasting system 510 of FIG. 11 is identical to the exemplary flow diagram illustrated in FIG. 10 for monitoring and adjusting the amount of airflow in the abrasive blasting system 410 of FIG. 9.

If the media reclaimer 514 includes a media reclaimer fan motor (not shown), the controller 550 may also control the media reclaimer fan motor. In such an embodiment, with the measuring of the static pressure in the blast enclosure 512, it would be desirable to control the speed of the media reclaimer fan motor and the motor 532 of the dust collector 516. In the previous examples (examples 1-3), if the media reclaimer 214, 314, 414 included a media reclaimer fan (not shown) with a media reclaimer fan motor (not shown), the media reclaimer fan motor could be operated (1) passively such that the media reclaimer fan motor is always running at the same speed with the controller 250, 350, 450 adjusting the speed of the motor 232, 332, 432 of the dust collector 216, 316, 416 or (2) actively such the media reclaimer fan and/or dust collector fan 228, 328, 428 are adjusted as needed by the controller.

Although described in connection with an exemplary computing system environment, embodiments of the aspects of the disclosure are operational with numerous other general purpose or special purpose computing system environments or configurations. The computing system environment is not intended to suggest any limitation as to the scope of use or functionality of any aspect of the disclosure. Moreover, the computing system environment should not be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with aspects of the disclosure include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, mobile telephones, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.

Embodiments of the aspects of the disclosure may be described in the genera context of data and/or processor-executable instructions, such as program modules, stored one or more tangible, non-transitory storage media and executed by one or more processors or other devices. Generally, program modules include, but are not limited to, routines, programs, objects, components, and data structures that perform particular tasks or implement particular abstract data types. Aspects of the disclosure may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote storage media including memory storage devices.

In operation, processors, computers and/or servers may execute the processor-executable instructions (e.g., software, firmware, and/or hardware) such as those illustrated herein to implement aspects of the disclosure.

Embodiments of the aspects of the disclosure may be implemented with processor-executable instructions. The processor-executable instructions may be organized into one or more processor-executable components or modules on a tangible processor readable storage medium. Aspects of the disclosure may be implemented with any number and organization of such components or modules. For example, aspects of the disclosure are not limited to the specific processor-executable instructions or the specific components or modules illustrated in the figures and described herein. Other embodiments of the aspects of the disclosure may include different processor-executable instructions or components having more or less functionality than illustrated and described herein.

The order of execution or performance of the operations in embodiments of the aspects of the disclosure illustrated and described herein is not essential, unless otherwise specified. That is, the operations may be performed in any order, unless otherwise specified, and embodiments of the aspects of the disclosure may include additional or fewer operations than those disclosed herein. For example, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the disclosure.

It will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above products without departing from the scope of the claims, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

What is claimed is:
 1. An abrasive blasting system comprising: a blast enclosure configured to receive a component therein to be blasted by an abrasive media; a dust collector fluidly coupled to the blast enclosure and configured to collect dust from the blast enclosure generated by blasting of the component by the media, the dust collector including a filter and a fan having a motor, the filter disposed upstream of the fan, the fan being configured to draw air and dust from the blast enclosure into the dust collector and draw air through the filter to separate the dust from the air; a sensor configured to monitor a condition of the abrasive blasting system and to generate a condition signal corresponding to the condition; and a controller configured to receive the condition signal and to control the fan based on the condition signal.
 2. The abrasive blasting system of claim 1, wherein the sensor is a current sensor and the condition is a current drawn by the motor.
 3. The abrasive blasting system of claim 1, wherein the sensor is disposed upstream of the fan.
 4. The abrasive blasting system of claim 1, wherein the sensor is disposed downstream of the fan.
 5. The abrasive blasting system of claim 1, wherein the sensor is one of a pitot tube sensor or a static pressure sensor and the condition is one of a velocity of the air or a pressure of the air.
 6. The abrasive blasting of claim 1, further comprising a media reclaimer fluidly connected to and disposed between the blast enclosure and the dust collector, the media reclaimer configured to separate the abrasive media from the dust, wherein the controller is configured to control the fan based on the condition signal to maintain a sufficient amount of airflow through the media reclaimer to ensure an optimal amount of media is separated from the dust.
 7. The abrasive blasting system of claim 1, wherein the controller is configured to estimate an end of a life of the filter based on the condition signal.
 8. The abrasive blasting system of claim 7, wherein the controller is configured to determine when the end of life of the filter has been reached based on the condition signal.
 9. An abrasive blasting system comprising: a blast enclosure configured to receive a component therein to be blasted by an abrasive media; a dust collector fluidly coupled to the blast enclosure and configured to collect dust from the blast enclosure generated by blasting of the component by the media, the dust collector including a filter and a fan having a motor, the filter disposed upstream of the fan, the fan being configured to draw air and the dust from the blast enclosure into the dust collector and draw air through the filter to separate the dust from the air; a sensor configured to monitor a condition of the abrasive blasting system and to generate a condition signal corresponding to the condition; and a controller configured to estimate an end of a life of the filter based on the condition signal.
 10. The abrasive blasting system of claim 9, wherein the sensor is a current sensor and the condition is a current drawn by the motor.
 11. The abrasive blasting system of claim 9, wherein the sensor is disposed upstream of the fan.
 12. The abrasive blasting system of claim 9, wherein the sensor is disposed downstream of the fan.
 13. The abrasive blasting system of claim 9, wherein the sensor is one of a pitot tube sensor or a static pressure sensor and the condition is one of a velocity of the air or a pressure of the air.
 14. The abrasive blasting system of claim 9, wherein the controller is configured to determine when the end of life of the filter has been reached based on the condition signal.
 15. The abrasive blasting system of claim 9, further comprising a media reclaimer fluidly connected to and disposed between the blast enclosure and the dust collector, the media reclaimer configured to separate the abrasive media from the dust, wherein the controller is configured to control the fan based on the condition signal to maintain a sufficient amount of airflow through the media reclaimer to ensure an optimal amount of media is separated from the dust.
 16. A method of operating an abrasive blasting system, the method comprising: blasting a component within a blast enclosure by an abrasive media; moving air with a fan having a motor from the blast enclosure to a dust collector to collect dust from the blast enclosure, the dust collector having a filter; monitoring a condition of the abrasive blasting system; and controlling the fan based on the condition.
 17. The method of claim 16, wherein the condition is a current drawn by the motor of the fan.
 18. The method of claim 17, said controlling the fan includes increasing the speed of the fan to maintain a threshold level of airflow through the abrasive blasting system.
 19. The method of claim 16, wherein the condition is one of a velocity of the air or a pressure of the air.
 20. The method of claim 19, said controlling the fan includes increasing the speed of the fan to maintain a threshold level of airflow through the abrasive blasting system. 